USPTO Patents Application 10018419

JMARaa-dPgr/PTO P9 OCT 200t

U.S. DEPARTMENT OF CX3MMERCE PATElST AND TRADEMARK OFFICE

^m^SMITTAL LETTER TO THE UNITED STATES
" DESIGNATED/ELECTED OFFICE (DO/EO/US)
CONCERNING A FILING UNDER 35 U.S.C. 371

ATTORNEY'S DOCKET NUMBER
DE 1311

U.S. APPLICATION NO. (l¥ KNOWN, SEE 37 CFR

10/01847^

INTERNATIONAL APPLICATION NO.
PCT/KROO/00403

INTERNATIONAL FILING DATE
28 APRIL 2000

PRIORITY DATE CLAIMED

28 APRIL 1999

TITLE OF INVENTION

FIBER REINFORCED EPOXY RESIN PRODUCT AND METHOD FOR THE MANUFACTURE THEREOF

APPLICANT(S) FOR DO/EOAJS
Dong Bo YANG

Applicant herewith submits to the United States Designated/Elected Office (DO/EO/US) the following items and other information:
S This is a FIRST submission of items concerning a filing under 35 U.S.C. 371.
□ This is a SECOND or SUBSEQUENT submission of items concerning a filing under 35 U.S.C. 371.

S This is an express request to begin national examination procedures (35 U.S.C. 371(f)). The submission must include itens (5),

(6), (9) and (24) indicated below.
g| The US has been elected by the expiration of 19 months from the priority date (Article 3 1).
^ A copy of the International Application as filed (35 U.S.C. 371 (c) (2))

a. K is attached hereto (required only if not communicated by the International Bureau).

b. D has been communicated by the International Bureau.

c. □ is not requked, as the application was filed in tiie United States Receiving Office (RO/US).
K An English language translation of tiie International Application as filed (35 U.S.C. 371(c)(2)).

a. K is attached hereto.
* b. □ hasbeenpreviously submitted under 35 U.S.C. 154(d)(4).

gl Amendments to the claims of the International Application under PCT Article 19 (35 U.S.C. 371 (c)(3))

a. □ are attached hereto (required only if not commimicated by the International Bureau).

b. □ have been communicated by the International Bureau.

c. □ have not been made; however, the time limit for making such amendments has NOT expired.

d. H have not been made and will not be made.

□ An English language translation of the amendments to the claims under PCT Article 19(35U.S.C.371 (c)(3)).
m An oath or declaration of the inventor(s) (35 U.S.C. 371 (c)(4)).

□ An English language translation of the annexes of the International Preliminary Examination Report under PCT
Article 36 (35 U.S.C. 371 (c)(5)).

K Acopy of Ifae International Preliminary Examination Report (PCT/IPEA/409).
H A copy of the International Search Report (PCT/ISA/210).
Items 13 to 20 below concern document(s) or information included:

An Information Disclosure Statement under 37 CFR 1.97 and 1.98.

An assignment document for recording. A separate cover sheet in compliance with 37 CFR 3.28 and 3.31 is included.
A FIRST preliminary amendment.
A SECOND or SUBSEQUENT preliminary amendment.
A substitute specification.

A change of power of attorney and/or address letter.

A computer-readable form of the sequence listing in accordance with PCT Rule 13ter.2 and 35 U.S.C. 1.821 - 1.825.
A second copy of the published international application under 35 U.S.C. 154(d)(4).

A second copy of the Enghsh language translation of the international appHcation under 35 U.S.C. 154(d)(4).
Certificate of Mailing by Express Mail
Other items or information:

PCT Demand Form
PCT Request Form
Specifications, Claims and abstract

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Page 1 of 2

PCTUS1/REV03

U.S. APPUCATIOl

INTERNATIONAL APPLICATION NO.
PCT/KROO/00403

ATTORNEY'S DOCKET NUMBER
D£ 1311

"* The following fees are submitted:.
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USPTO but International Search Report prepared by the EPO or JPO

International preliminary examination fee (37 CFR 1.482) not paid to USPTO
but international search fee (37 CFR 1.445(a)(2)) paid to USPTO

International preliminary examination fee (37 CFR 1.482) paid to USPTO

but all claims did not satisfy provisions of PCT Article 33(l)-(4)

International preliminary- exa
and all claims satisfied provij

lination fee (37 CFR 1.482) paid to USPTO

ons of PCT Article 33(l)-(4)

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SEND ALL CORRESPONDENCE TO:

David A. Einhorn, Esq.
ANDERSON, KILL & OLICK, P.C.
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SIGjfiATURE
Eugene Lieberstein

NAME
24-645

REGISTRATION NUMBER
October 29, 2001

Page 2 of 2

10/018419

""Lu JCiSBec-dKnypTo 29ocr2ooi

FIBER REINFORCED EPOXY RESIN PRODUCT AND METHOD FOR THE
MENUFACTURE THEREOF

This application is a Continuation Application of PCT
International Application No. PCT/KROO/00403 filed on April
28, 2000, which designated the United States.

Field of the Invention

The present invention relates to a fiber reinforced
epoxy resin product and a method for manufacturing thereof;
more particularly, to a fiber reinforced epoxy resin product
comprising a hardened epoxy resin mixture including epoxy
resin, silica and reinforcing fiber materials such as glass
fiber, carbon fiber, aramid fiber or Kevlar fiber, and at
least one layer of fiber glass roving cloth and a method for
manufacturing thereof.

Background of the Invention

Conventionally, various methods such as a steel plate
bonding method, prestressing method and cross section
increasing method are used for reinforcing and repairing a
concrete structure .

The steel plate bonding method is adopted for
reinforcing bending strength of decks or shear strength of

piers of a bridge. The prestressing method is used with
concrete casting when the amount of prestress is less than a
desired level. The cross section increasing method is
applied when the amount of reinforcing rods and the cross
section of the concrete structure is insufficient.

Recently, the steel plate bonding method is most
widely used among above-mentioned methods. In this method,
steel plates are bonded to concrete surfaces via adhesive
material such as epoxy resin in order to assure the
transmission of shear stress and sufficient adhere strength
between the concrete surfaces and the steel plates.

In such a method, however, continuous maintenance is
needed to keep the sufficient adhere strength between the
concrete surfaces and steel plates. And, where the concrete
structure is exposed to seawater, it is difficult to achieve
sufficient reinforcement or repair because of corrosion of
the steel plates or problems related to durability of
adhesive material. Also, the structural load increases as
the number of the steel plates increases, wherein steel has
a relatively high specific weight. Further, the steel
plates are usually bonded to a bottom surface of the
structure. Thus, lots of working hours and workers are
needed, thereby increasing the costs.

By utilizing fiber reinforced plastics (FRP) panels
instead of steel plates, the problems caused by corrosion
can be prevented. However, FRP panels have such a low

strength that they function just as a cover for concrete
surfaces .

In order to solve these problems, there have been
suggested several improved methods such as those described
in Korean Laid-open Publication No. 174,161 having the title
of "A epoxy resin panel for reinforcing concrete structure
and a method for the manufacture thereof" filed by the
applicant or Japanese Laid-open Publication No. 4-67 94 6
having the title of "Thermosetting resin composite panel".
The resin panels suggested by these methods include metal
wires as a reinforcing material. However, the metal wires
are corroded after a long period of use, which makes the
binding strength between resin material and wires decreased
and, in turn, cracks or delamination is developed in the
resin panels. Further, weatherability and chemical

resistance of the metal wires are not sufficient and, most
of all, physical properties such as tension strength or
compressive strength are deteriorated by the weakened
binding strength.

Summary of the Invention

It is, therefore, an object of the present invention
to provide a fiber reinforced epoxy resin product having
improved physical and chemical properties and also having
better weatherability and chemical resistance by mixing

epoxy resin with fiber chops and casting the mixture into a
mold in which at least one layer of glass fiber roving cloth
is arranged. It is another object of the present invention
to provide a method for manufacturing such a fiber
5 reinforced epoxy resin product.

A fiber reinforced epoxy resin panel according to the
present invention can be used in various fields such as, for
example, 1) reinforcement and repair of various kinds of
'■^^ concrete structures, 2) protection of surfaces of concrete

10 structures from seawater, foul water, damages by freeze-thaw
''f^: or other chemical actions, 3) reinforcement of tunnel

K linings, 4) corner casting panels for container terminal, 5)

m

15 vehicle block, or the likes.

g In accordance with a preferred embodiment of the

i|| 15 present invention, there is provided a method for

5

manufacturing a fiber reinforced epoxy resin product,
comprising the steps of providing a mold for the product;
applying a release agent to inner surfaces of the mold;
providing at least one layer of glass fiber roving cloth in

20 the mold; casting an unhardened epoxy resin mixture in the
mold; pressing the epoxy resin mixture in the mold;
hardening the epoxy resin mixture in the mold under a
temperature between about 20 °C and about 80°C for more than
30 minutes; releasing the hardened epoxy resin mixture from

25 the mold; and curing the hardened epoxy resin mixture under
a temperature between about 20°C and 35°C for about 24 hours

- 4 -

to form the product.

In accordance with another preferred embodiment of the
present invention, there is provided a fiber reinforced
epoxy resin product, comprising a hardened epoxy resin
5 mixture including epoxy resin, silica and a fibrous material,
wherein the fibrous material is a material selected from the
group consisting of glass fiber, carbon fiber, aramid fiber
and Kevlar fiber or a mixture thereof; and at least one
!^ layer of glass fiber roving cloth is arranged parallel to

1^ 10 each other in the hardened epoxy resin mixture.
I

'M Brief Description of the Drawings

Q- ■

1=11 The above and other objects and features of the

]n

^ 15 present invention will become apparent from the following
'^'^ description of preferred embodiments given in conjunction

with the accompanying drawings, in which:

Fig. lA to IF show an exemplified process of
manufacturing the fiber reinforced epoxy resin product in
20 accordance with the present invention;

Fig. _2 illustrates a cross-sectional view of a fiber

reinforced epoxy resin panel manufactured in accordance with
the method of the present invention;

Fig. describes a cross-sectional view of a fiber
25 reinforced epoxy resin panel bonded to a surface of a
concrete structure for reinforcing in accordance with the

- 5 -

present invention;

Fig. 4A represents a plan view of a corner casting
panel as an application of the fiber reinforced epoxy resin
product in accordance with the present invention;
5 Fig. 4B is a side view of the corner casting panel

shown in Fig. 4A;

Fig. 4C offers the installation of the panel in
accordance wTtli the present invention;
!>B* Fig. 5A to 5C provides vehicle blocks manufactured by

10 the method in accordance with the present invention;

Fig. 6 sets forth an elevation view of the installed
vehicle blo"cks; and.

Fig. 7 portrays a cross-sectional view taken along
line I-I in Fig. 6.

•3 ■

m 15

□ Detailed Description of the Preferred Embodiments

Fig. lA to Fig. IF illustrate an exemplified process
of manufacturing a fiber reinforced epoxy resin product in
20 accordance with the present invention.

Step (a) : a rectangular-shape mold (10) having a
predetermined size is provided and dirt or other unnecessary
materials are removed therefrom. The mold (10) can have
various sizes and shapes depending on the use of a finished
25 product. Preferably, the mold (10) is made of metal for
durability and can be utilized again after cleaning inner

- 6 -

surfaces thereof.

Step (b) : a release agent (20) of conventional type is
coated to inner surfaces of the mold (10) with a constant
thickness. The release agent (20) facilitates the

separation of the finished product from the mold.

Step (c) : a first fiber mesh (30A) having meshes of
predetermined sizes is allocated above the release agent
(20) in the mold (10) . Before this, the first fiber mesh
(30A) is cut into a suitable size to fit in the mold and may
be impregnated with epoxy resin in order to enhance the
strength. Preferably, the epoxy resin has physical

properties as followings: less than or equal to 380 mPas
(380 csp) of viscosity, about 15 minutes of gel time, more
than or equal to 1000 kg/cm^ of compressive strength, more
than or equal to 500 kg/cm^ of bending strength, more than
or equal to 800 kg/cm^ of shear strength, more than or equal
to 130 kg/cm^ of adhesive strength, more than or equal to
0,02 of tensile fracture strain rate; 1.0 X 10"^ to 2.0 X 10"
^ cm/cm/ °C of coefficient of expansion; 50 to 75 °C of heat
deflection degree.

Step (d) : Epoxy resin is mixed with reinforcing fiber
materials in a ratio of 9 to 1 and the mixture is cast onto
the first fiber mesh (30A) which was impregnated with the
epoxy resin (a first casting process) . The mixture includes
the epoxy resin, a small amount of cement, silica and
chopped reinforcing fiber material. The reinforcing fiber

material is a material selected from the group consisting of
glass fiber, carbon fiber, agamid fiber and Kevlar fiber or
the mixture thereof.

Preferably, the epoxy resin has following properties:
1.15 to 1.20 of specific weight; M70 to M80 of hardness;
19,000 to 24, 000 cps of viscosity; less than or equal to
0.14% of absorptivity; less than or equal to 1.1% of
shrinkage; and 180 to 230 of epoxy equivalent. The
preferable properties of the silica are as followings: more
than or equal to 95% of purity; 2.25 to 2.65 of specific
weight; 6.5 to 7.0 of Mohs hardness and 7 to 9 pH.

Step (e) : After the first casting process, a second
fiber mesh (30B) having same size and shape with the first
fiber mesh (30A) is allocated in the mold and the epoxy
resin mixture is cast thereon (a second casting process) .
When the second casting process is finished, a third fiber
mesh (30C) is allocated parallel to the first and second
fiber mesh {30A, 30B) in the mold. The number of fiber mesh
layers may be varied depending on the use of a finished
epoxy resin product. When it is used for reinforcement and
repair of concrete structures, the finished epoxy resin
product preferably has a plurality of layers and, e.g., the
number of layers and the amount of the fibers are decided
according to desired strength increase which may be
calculated by structural analysis.

When the first and second casting process is finished.

vibrations are applied to the mold (10) by a vibrator such
that the fiber meshes are moved into the epoxy resin mixture
as shown in Fig. IE.

After the vibrating process, the epoxy resin mixture
5 is hardened under a temperature of 60 °C for 30 minutes, and
then pressed with a load of 1000 kg. Next, the epoxy resin
mixture is hardened at a temperature of 80C for 3 hours.

Step (f ) : The hardened epoxy resin mixture is released

•3 from the mold (10) and cured under a temperature between 25

□

i-* 10 to 30 °C for a predetermined period to form a fiber
1^ reinforced epoxy resin product (1) . The mold (10) can be

used again after the dirt is removed therefrom.
r.=. Fig. 2 shows a cross-sectional view of a fiber

reinforced epoxy resin panel manufactured in accordance with
'G 15 the method of the present invention.

i** Fig. 3 is a cross-sectional view of a fiber reinforced

epoxy resin panel bonded to a surface of a concrete
structure for reinforcing.

First, a surface of a concrete structure (80) is
20 pretreated for the reinforcement. A surface area to be
reinforced and repaired is determined and the compression
strength of the concrete structure is measured. The size of
reinforcing panel is determined depending on the desired
strength. Deteriorated parts of the concrete structure are
25 removed and the surfaces are pretreated. Corroded steel
reinforcing bars are repaired if required.

- 9 -

Next, the fiber reinforced epoxy resin panel (1) is
fixed to the surface of concrete structure (80) via an
anchor bolt or a chemical anchor bolt (84) . The epoxy resin
panel (1) is anchored to the surface with a gap of about 2
5 to about 6 mm by means of spacers. Adhesive epoxy resin
will be injected into the gap between the panel and the
surface. It is preferable that the gap between the panel
and surface is as small as possible. Heads of the anchor
O bolts (84) are removed or covered by anchor caps to prevent

I** 10 corrosion. It is preferable that a distance from the anchor

m

M bolt (84) to the edge of the panel does not exceed 100 mm

and a length of the anchor bolt is at least 2 to 3 times a

^ depth of deteriorated parts. About 9 bolts are installed

per 1 and generally a distance between the bolts is 30 cm.

■JJ- 15 Thereafter, adhesive epoxy resin (90) is injected into

^ the gap. Before the injection, peripheries of the panel (1)

are sealed with a sealant which is preferably the same type
as the adhesive epoxy resin. Preferably, the adhesive epoxy
resin (90) has same properties as the epoxy resin
20 constituting the epoxy resin mixture but has lower viscosity.
It is preferable to examine the properties of the adhesive
epoxy resin (90) and working condition by mock-up test. The
adhesive epoxy resin (90) is injected into the gap by an
injection pressure of, e.g., 0.5 to 2.5 kg/cm^. Injection
25 process starts at a low pressure and the pressure is slowly
increased in order to prevent the generation of air bubbles.

- 10 -

This process is performed at a temperature of 5 to 30°C.

After the injection process is finished, the adhesive
epoxy resin is cured for 3 days. The epoxy resin panels are
protected from rainwater or dirt by covering it with vinyl
sheet or the like. Heads of anchor bolts can be removed for
good appearance.

Fig. 4A shows a plan view of a corner casting panel as
an application of the fiber reinforced epoxy resin product
in accordance with the present invention. Also, Fig. 4B is
a side view thereof and Fig. 4C shows the installation of
the panel.

A corner casting panel (100) is an article for
protecting surfaces (110) of container terminal from being
damaged by corner portions of container boxes. These panels
(100) are arranged to support the corners of the container
boxes .

These corner casting panels are manufactured by the
same process as above described except that more fiber mesh
layers are included and compositions of some components are
different in order to increase the strength. The panels can
be manufactured in various sizes such as, e.g., {420 mm X
1350 mm X 20 mm), {420 mm X 600 ram X 20 mm} or {1000 mm X
1350 mm X 20 mm} .

Figs. 5A to 5C show vehicle blocks manufactured by the
method in accordance with the present invention.

These vehicle blocks (200, 200A, 200B) are

manufactured by the same process as above described in
various sizes. The vehicle blocks (200, 200A, 200B) have
through holes (212) for fixing bolts (210) . Preferably, the
fixing bolts (210) are more than 2 times longer than the
5 heights of the blocks (200, 200A, 200B) . The numbers of the
through holes (212) can be changed depending on the length
of the block.

^ Fig. 6 is an elevation view of the installed vehicle

'jJ blocks. Fig. 7 shows a cross-sectional view taken along

i-^ 10 line I-I in Fig. 6.

m

,|5 These vehicle blocks are manufactured by the same

ijj process as above described except that the epoxy resin

mixture preferably has compositions as followings: 10 to 30
jSj wt% of epoxy resin, 20 to 39 wt% of silica, 30 to 68 wt% of

15 rubbles and 0.01 to 1 wt% of reinforcing materials, and more

preferably, 13.64 wt% of epoxy resin, 39.59 wt% of silica,

4 6.70 wt% of rubbles and 0.07 wt% of reinforcing fiber

materials .

Preferably, the fiber mesh has properties as
20 followings: 550 to 610 g/m^ of weight, more than or equal to
6.3 of density, more than or equal to 1,500 kg/mm^ of
tensile strength and more than or equal to 1,295 kg/mm^ of
bending strength.

Also, the epoxy resin mixture may include inorganic
25 materials having refractory and self -extinguishing
characteristics, e.g., aluminum hydroxide, antimony oxide or

- 12 -

hydro bromide. In order to maintain the structural strength,
it is preferable that the epoxy resin mixture does not
include the inorganic materials more than 5 wt% relative to
the total weight of the epoxy resin mixture.
5 As shown in the drawings, the vehicle blocks (200,

200C) are aligned in a predetermined interval. The interval
is corresponding to a width of vehicles and the vehicle
blocks (200B) having inclined surface are allocated at both

Q ends of the vehicle block line.

10 The vehicle blocks (200) are fixed to desired places

'2 with the bolts (210) after surfaces (300) of the places are

cleaned. Next, peripheries of each block are sealed by

^ sealant and then resin inlet and air outlet are formed.

O Thereafter, adhesive epoxy resin (220) is injected into an

m .

ill 15 interface between the surface and the block for preventing

o

1-4, permeation of water and assuring that the blocks are firmly

fixed to the surfaces. Preferably, an adhesive epoxy resin
layer has a thickness of about 2 mm to 6 ram. Injection
process starts at a lower pressure which is increased to

20 higher pressure gradually and slowly in order to prevent
generation of air bubbles. It is preferably that the
injection pressure is 0,5 to 2.5 kg/cm^. The adhesive epoxy
resin has the same properties as above described except that
it has lower viscosity and a gel time of about 3 hours.

25 After the injection process, the adhesive epoxy resin

is cured more than 3 hours. An epoxy based paint may be

- 13 -

applied to the surface of the vehicle block. Above
described process also can be applied to manufacture the
corner casting panels.

Examples

Examples of manufacturing the concrete reinforcing
panels and vehicle blocks are described hereinafter.

Example 1

A mold having a size of 1000 mm X 1000 mm X 11 mm was
prepared. A release agent was applied to inner surfaces of
the mold. At least three layers of fiber mesh were arranged
in the mold. Thereafter, an epoxy resin mixture including
30.1 wt% of epoxy resin, 0.5 wt% of cement, 69.3 wt% of
silica and 0.1 wt% of chopped fibers was cast into the mold
and then the mold was vibrated. After hardening process at
a temperature of 60 °C for 30 minutes, the epoxy resin
mixture was pressurized with a load of 1,000 kg. The epoxy
resin mixture was further hardened at a temperature of 80 °C
for 3 hours and then released from the mold. The hardened
epoxy resin mixture was cured at a temperature of 25 to 30 °C
and a humidity of 40 to 50% for 3 days. Properties of
finished epoxy resin panels were tested and a result
obtained is as followings:

- 14 -

TABLE 1

Mechanical properties

Test result

Remarks

Compression strength (kg/cm^)

800

fracture
strain rate
0. 017

Direct tensile strength
(kg/cm^)

340

fracture
strain rate
0.017

Bending strength (kg/cm^)

400

Modulus of
Elasticity

Compression
(kg/cm^)

74, 000

Tension
(kg/cm^)

34,000

Poisson' s
ratio

Compression

0 . 34

Tension

0.22

Fracture
strain rate

Compression

0 . 020

0.017 - 0.037

Tension

0.010

0.010 - 0.014

Coefficient of thermal
expansion

6.5 X 10"^

Weatherablilty

Cured in the
water

Substantially
not affected

For 3 months

Exposed to
the air

Substantially
not affected

For 3 months

Chemical resistance

Strong
resistance to
acid and
alkali

As shown in table 1, the compression strength and

tensile strength of the fiber reinforced epoxy panel is
higher than those of concrete and the bending strength is
also relatively high.

It was found from the specimens cured in the water and
in the air at a low temperature that the properties of the
epoxy resin product in accordance with the present invention

- 15 -

were not affected by the weather conditions such as
temperature and humidity, and the period disposed in the
water. The epoxy resin product also had strong resistance
to the acids and alkalis. It was thus proved that the epoxy
5 resin product was appropriate to use in places under severe
condition such as seawater, sewage and exhaust gas of
vehicles .

Example 2

i'^ 10 A mold having a size of 800 mm X 1500 mm X 11 mm was

1

•.f« prepared. A release agent was applied to inner surfaces of

iQ the mold. At least three layers of fiber mesh were arranged

i-i in the mold. Thereafter, an epoxy resin mixture including

iSl 23.9 wt% of epoxy resin, 1.5 wt% of cement, 74.5 wt% of

15 silica and 0.1 wt% of chopped fibers was cast into the mold
i** and then the mold was vibrated. After hardening process at

a temperature of 60°C for 30 minutes, the epoxy resin
mixture was pressurized with a load of 1,000 kg. The epoxy
resin mixture was further hardened at a temperature of 8 0°C
20 for 3 hours and then released from the mold. The hardened
epoxy resin mixture was cured at a temperature of 25 to 30 °C
and a humidity of 40 to 50% for 3 days. Properties of
finished epoxy resin panels were tested and the results were
substantially same as those in Table 1.

25

- 16 -

Example 3

A steel mold having a size of 170 mm X 150 mm X 1000
mm was prepared. A release agent, e.g., 700-NC or PS-100,
was applied to inner surfaces of the mold. Layers of fiber
mesh were arranged in the mold. Thereafter, an epoxy resin
mixture including epoxy resin, silica, reinforcing fiber,
rubbles, cement and inorganic materials was cast into the
mold and then air bubbles were removed from the mold. The
remaining amounts of the air bobbles were below 4%. The
epoxy resin mixture was pressurized with a load of 800 to
1,000 kg and hardened for 1 to 3 hours and then released
from the mold. The hardened epoxy resin mixture was cured
at a temperature of 25 to SCC and a humidity of 40 to 50%
for 24 hours- The properties of the finished epoxy resin
vehicle blocks were tested and a result obtained is as
f ollowings :

TABLE 2

Properties

Test results

Concrete

Compression strength (kg/cm^)

1128

300

Direct tensile strength
(kg/cm^)

360

340

Bending strength (kg/cm^)

450

400

Weatherability

Cured in the
water

Substantially
not affected

Affected

Exposed to
the air

Substantially
not affected

Affected

Chemical resistance

Strong
resistance to
acid and
alkali

Weak

- 17 -

As shown in Table 2, the compression strength and
tensile strength of fiber reinforced epoxy resin vehicle
block are higher than those of concrete and the bending
5 strength is also relatively high. Also, the durability was
better than that of concrete. It was found from the
specimens cured in the water and in the air at a low
temperature that the properties of the epoxy resin product
i,^ in accordance with the present invention were not affected

10 by the weather conditions such as temperature and humidity,
and the period disposed in the water. The epoxy resin
:J product also had strong resistance to the acids and alkalis.

'(5 It was thus proved that the epoxy resin product was

if

!=™ appropriate to use in places under severe condition such as

15 seawater, sewage and exhaust gas of vehicles.
Q While the invention has been shown and described with

respect to the preferred embodiments, it will be understood
by those skilled in the art that various changes and
modifications may be made without departing from the spirit
20 and scope of the invention as defined in the following
claims .

- 18 -

What is claimed is:

1. A method for manufacturing a fiber reinforced epoxy resin
product, comprising:

providing a mold for the product;

applying a release agent to inner surfaces of the mold;
providing at least one layer of glass fiber roving cloth
in the mold;

casting an unhardened epoxy resin mixture in the mold;

pressing the epoxy resin mixture in the mold;

hardening the epoxy resin mixture in the mold under a
temperature between about 20 °C and about 80 °C for more than
30 minutes;

releasing the hardened epoxy resin mixture from the mold;
and

curing the hardened epoxy resin mixture under a
temperature between about 20°C and 35°C for about 24 hours
to form the product.

2. The method of claim 1, wherein the epoxy resin mixture
includes epoxy resin, silica and reinforcing fibrous
material, the reinforcing fibrous material being a material
selected from the group consisting of glass fiber, carbon
fiber, aramid fiber and Kevlar fiber or a mixture thereof.

3. The method of claim 2, wherein the epoxy resin mixture

further includes cement.

4. The method of claim 2, wherein the epoxy resin mixture
further includes an inorganic material having refractory and
self-extinguishing characteristics .

5. The method of claim 4, wherein the inorganic material is
selected from the group consisting of Aluminum hydroxide,
antimony oxide and hydro bromide.

6. The method of claim \, the method further comprising a
step of impregnating at least one layer of the glass fiber
roving cloth with epoxy resin.

7. The method of claim 1, the method further comprising a
step of removing air bubbles from the unhardened epoxy resin
mixture .

8. The method of claim 1, wherein the removal of the air
bubbles is performed by vibrating the mold.

9. A fiber reinforced epoxy resin product, comprising.

a hardened epoxy resin mixture including epoxy resin,
silica and a fibrous material, the fibrous material being a
material selected from the group consisting of glass fiber,
carbon fiber, aramid fiber and Kevlar fiber or a mixture

thereof;

at least one layer of glass fiber roving cloth arranged
parallel to each other in the hardened epoxy resin mixture.

10. A method for manufacturing a fiber reinforced epoxy
resin product, comprising:

providing a mold for the product;

applying a release agent to inner surfaces of the mold;

providing at least one layer of glass fiber in the mold;

casting an unhardened epoxy resin mixture in the mold;

pressing the epoxy resin mixture in the mold;

hardening the epoxy resin mixture in the mold under a
temperature between about 20 °C and about 80 °C for more than
30 minutes;

releasing the hardened epoxy resin mixture from the mold;
and

curing the hardened epoxy resin mixture under a
temperature between about 20 "C and 35 °C for about 24 hours
to form the product.

11. A method for manufacturing a fiber reinforced epoxy
resin panel, comprising:

providing a mold for the panel;

applying a release agent to inner surfaces of the mold;
providing at least three layers of glass fiber roving
cloth in the mold;

- 21 -

casting an unhardened epoxy resin mixture in the mold;

pressing the epoxy resin mixture in the mold;

hardening the epoxy resin mixture in the mold under a
temperature between about 60 °C and about 80 °C for more than
30 minutes;

releasing the hardened epoxy resin mixture from the mold;
and

curing the hardened epoxy resin mixture under a
temperature between about 25 °C and 30 °C and a humidity
between about 40% and about 50% for about three days to form
the panel.

12. The method of claim 11, wherein the epoxy resin mixture
includes epoxy resin, silica and reinforcing fibrous
material, the reinforcing fibrous material being a material
selected from the group consisting of glass fiber, carbon
fiber, aramid fiber and Kevlar fiber or a mixture thereof.

13. The method of claim 11, the method further comprising a
step of impregnating at least one layer of the glass fiber
roving cloth with epoxy resin.

14. A fiber reinforced epoxy resin panel, comprising.

a hardened epoxy resin mixture including epoxy resin,
silica and a fibrous material, the fibrous material being a
material selected from the group consisting of glass fiber.

- 22 -

carbon fiber, aramid fiber and Kevlar fiber or a mixture
thereof;

at least three layer of glass fiber roving cloth arranged
parallel to each other in the hardened epoxy resin mixture.

15. A method for manufacturing a fiber reinforced epoxy
resin product, comprising:

providing a mold for the product;

applying a release agent to inner surfaces of the mold;

providing at least three layers of glass fiber roving
cloth in the mold;

casting an unhardened epoxy resin mixture in the mold;

pressing the epoxy resin mixture in the mold;

hardening the epoxy resin mixture in the mold under a
temperature between about 60°C and about 80°C for about one
to about three hours;

releasing the hardened epoxy resin mixture from the mold;
and

curing the hardened epoxy resin mixture under a
temperature between about 20 °C and 35 °C and a humidity
between about 30% and about 60% for about 24 hours to form
the product

16. A method of claim 15, the method further comprising a
step of removing air bubbles from the unhardened epoxy resin
mixture such that the amount of the air bubbles therein is

- 23 -

maintained below about 4%.

17. A method of claim 15;. wherein the epoxy resin mixture
includes epoxy resin, silica, rubbles and reinforcing
fibrous material, the reinforcing fibrous material being a
material selected from the group consisting of glass fiber,
carbon fiber, aramid fiber and Kevlar fiber or a mixture
thereof .

18. A method of claim. 17, wherein the epoxy resin mixture
further includes an inorganic material having refractory and
self -extinguishing characteristics .

19. A vehicle block structure having a predetermined height,

comprising :

a body including a hardened epoxy resin mixture and glass
fiber roving clothes, the hardened epoxy resin mixture
containing epoxy resin, silica, rubbles and reinforcing
fibrous material;

a plurality of through holes arranged in a direction of
elevation of the structure; and

a plurality of bolts having a length greater than the
height of the structure and being arranged in the through
hole to fix the structure to a desired place.

20. A vehicle block structure of claim 19, the structure

- 24 -

further comprising an adhesive epoxy resin layer in order to
fix the structure to a desired place.

1^

m
m

- 25 -

10/018419

FIG. IE

30B 30A

FIG. 2

30C

10/018419

i«3
ill

FIG. 3

80

JL

13

m

FIG.4A

100

/

FIG.4B

100

/

2i

10/01b419

FIG.4C

10/018419

10/018419

lii/018419

ANDERSON KILL & OLICK. P.C.
DECLARATION AND POWER OF ATTORNEY

This is a continuation application of International Application No. PCT/KROOrtMMOS filed on April 28, 2000 and designating the
United States of America.

As a below named inventor, I hereby declare that:

My residence, post office address and citizenship are as stated below next to my name.

i believe I am the original, first and sole Inventor (if only one name is listed at 201 below), or an original, first and joint inventor (if
plural names are listed at 201 et seq. below), of the subject matter which is claimed and for which a patent is sought on the
invenlion entitled FIBER REINFORCED EPOXY RESIN PRODUCT AND METHOD FOR THE MANUFACTURE THEREOF

the specification of which:
[Xlisattached hereto

[ ] was filed on as Application Serial No. (for declaration not accompanying application)

with amendment(s) filed on _(if applicable)

[ ] was filed as POT International Application Serial No on and was amended under PCT

Article 19 on .(If applicable)

I hereby state that I have reviewed and understand the contents of the above identified specification, including the claims, as
amended by any amendment tefened to above.

I acknowledge the duty to disclose information which is material to the examination of this applicafion in accordance with Title 37,
Code of Federal Regulations, §1 .56.

I hereby daim foreign priority benefite under Title 35, United States Code, §119/§172 of any foreign application(s) for patent or
inventor's certificate listed below and have also identified below any foreign application for patent or inventor's certificate having a
filing date before that of the application on which priority is claimed:

EARLIEST FOREIGN APPLICATION(S), IF ANY, FILED PRIOR TO THE FILING DATE OF THE APPLICATION

APPLICATION NUMBER

COUNTRY

DATE OF FILING
(day, month, year)

PRIORITY
CLAIMED UNDER
35U.S.C. 119/172

1999-15219

Republic of Korea

28, 04, 1999

YES [X] NO [ ]

1999-38063

Republic of Korea

08, 09, 1999

YES Ix] NO t ]

YES [ ] NO [ ]

I hereby daim ttie benefit under Title 35, PCT application(s) listed below and, insofar as the subject matter of each of the claims of
this application is not disclosed in the prior PCT application in the manner provided by the first paragraph erf Title 35, United States
Code §112, 1 acknowledge the duty to disdose material informatton as defined in Title 37, Code of Federal Regulations, §1.56(a)
which occun-ed between «ie filing date of the prior PCT application and the national filing date of this application:

FILING DATE

STATUS

APPLICATION NUMBER

PATENTED

PENDING

ABANDONED

PCT/KR00ra0403

28.04.2000

X

POWER OF ATTORNEY: As a named inventor. I hereby appoint Michael N. Meller (Reg. No. 20,779), Eugene Lieberstein (Reg.
No. ai^ASM'ichard B. Klar (Reg. Uo. 31,385) and Jack Matalon (Reg. No. 22,441) whose address is Anderson Kill & Olick,
P.C. 1251 Avenue of the Americas, New YSrR; New Yorit 10020-1182, as my attorneys, to prosecute tiiis applteation, and to
transact all business in tine Patent and Tradenrari< Office connected ttierewitti.

F -

SE^

n noRRFRPONDENCE TO: David A. Einhom, Esq.

DIRECT TELEPHONE NUMBER:

^Anderson Kill & Click, P.O. (212)278-1000

1251 Avenue of the Americas,
' NewYork, NY 10020

F

FULL NAME OF
INVENTOR

LAST NAME

YANG

FIRST NAME

Dong

MIDDLE NAME

Bo

0

RESIDENCE &
CITIZENSHIP

CITY

STATE OR FOREIGN COUNTRY

Republic of Korea

COUNTRY OF CITIZENSHIP

Republic of Korea

1

POST OFFICE

POST OFFICE ADDRESS

973-8, Dooam-dong, Buk-ku, Kwangju, Korea

STATE OR COUNTRY

Korea

ZIP CODE

500-100

FULL NAME OF
INVENTOR

LAST NAME

FIRST NAME

MIDDLE NAME

2
0

RESIDENCE &
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CITY

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COUNTRY OF CITIZENSHIP

2

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POST OFFICE ADDRESS

STATE OR COUNTRY

ZIP CODE

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2
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3

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2
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CITY

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4

POST OFFICE

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#

. ©■

FULL NAME OF
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LAST NAME

FIRST NAME

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2
0

RESIDENCE &
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CITY

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i ZIPCOUb

I hereby declare that all statements made herein of my own knowledge are true and that all statements made on infomiation and
belief are believed to be tme; and further that these statements were made with the knowledge that willful false statements and the
like SO made are punishable by fine or imprisonment, or both, under Section 18 of the United States Code and that such willful
false Statements may jeopardize the validity of the application or any patent issuing thereon.

SIGNATURE OF INVENTOR 201

SIGNATURE OF INVENTOR 202

SIGNATURE OF INVENTOR 203

DATE

DATE

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DATE

DATE